Method of Production for a Super Alloy

ABSTRACT

A method of production for a super alloy comprising the steps of: boring a hole at a depth ranging from about 12 kilometers to about 20 kilometers to create a shaft; manufacturing the shaft, where the shaft includes at least one guide way; maneuvering a super alloy production device to the base of the shaft; exposing a mixture of metals within the super alloy production device to extreme temperature and extreme pressure within the shaft; combining the mixture of metals within the super alloy production device to form a super alloy; removing the super alloy from the shaft with the super alloy production device; and incorporating the super alloy into at least one industrial device.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a method to produce a super alloy by deep drilling a hole and placing a mixture of metals at the base of the hole where natural forces promote the formation of the super alloy.

2. Description of Related Art

A supper alloy is a mixture of metals that when combined exhibit excellent mechanical strength, prevent deformation even at high temperatures, demonstrate good surface stability and efficiently resist corrosion and oxidation. They are commonly used in gas turbines engines, poppet valves of piston engines, space vehicles, submarines, nuclear reactors, military electric motors, racing and high-performance vehicles, chemical processing vessels, and bomb casings. Typically made from nickel, iron, cobalt, aluminum, chromium, molybdenum, tungsten, tantalum, titanium, zirconium, niobium, rhenium, carbon, boron and hafnium, the super alloys demonstrate unique characteristics depending on the type of elements used.

The method of manufacture for super alloys is relied heavily on both chemical and process innovations and has been driven primarily by the aerospace and power industries. Currently, within the market there are limited options for an engineering tool that combines the benefit of impactful tensile stress with high temperature sustainability. While these methods are purposeful in the production of super alloys, they do not push the boundaries of what could be used for super alloy production. Conventional approaches to alloy construction typically do not always incorporate the most advanced technology available.

It would be beneficial in the art to provide a method of production of a super alloy that incorporates the latest technological processes. It would also be desirable in the art to provide a method of super alloy production that involves harnessing the natural forces of the earth to further the metal combination.

SUMMARY OF THE INVENTION

In view of the foregoing disadvantages inherent in the prior art, the general purpose of the present invention is to provide a method of production for a super alloy, configured to include all of the advantages of the prior art, and to overcome the drawbacks inherent therein. To achieve the above objects, in an aspect of the present invention, a method of production for a super alloy is described comprising the steps of: boring a hole at a depth ranging from about 12 kilometers to about 20 kilometers to create a shaft; manufacturing the shaft, where the shaft includes at least one guide way; maneuvering a super alloy production device to the base of the shaft; exposing a mixture of metals within the super alloy production device to extreme temperature and extreme pressure within the shaft; combining the mixture of metals within the super alloy production device to form a super alloy; removing the super alloy from the shaft with the super alloy production device; and incorporating the super alloy into one or more industrial devices.

These together with other aspects of the present invention, along with the various features of novelty that characterize the present invention, are pointed out with particularity in the claims annexed hereto and form a part of this present invention. For a better understanding of the present invention, its operating advantages, and the specific objects attained by its uses, reference should be made to the following descriptive matter.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to a method to produce a super alloy by deep drilling a hole and placing a mixture of metals at the base of the hole where natural forces promote the formation of the super alloy. The present invention provides a method of producing a metal alloy wherein a mixture of metals is lowered into the earth. At extreme depths, the mixture of metals is then exposed to extreme pressure and heat which enables the mixture to combine and create a super alloy.

In one particular embodiment, the process begins by boring a shaft into the earth which may reach a depth ranging from 12-20 kilometers. Then a super alloy production device is maneuvered into the shaft for exposure to extreme temperatures and pressure. The shaft may possess both centered and geared guide ways to lower the super alloy production device through the shaft to the shaft base. At these exemplary depths, noise and vibrations are minimized as compared to working at shallower depths or on the surface. The super alloy production device enables the metal mixture to withstand high temperatures and stress as the metals combine for super alloy formation.

The mixture of metals may be a combination metals or metal alloys to create the preferred super alloy composition. In a preferred embodiment, the mixture of metals creates a molten state, whereby the required chemical process for super alloy production is faster and more efficient than in the solid metal form. In one exemplary method, the super alloy produced may be nickel based, whereas in an alternative method the super alloy may be aluminum based. Other metals used may be iron, cobalt, chromium, molybdenum, tungsten, tantalum, titanium, zirconium, niobium, rhenium, carbon, boron, and hafnium. Due to the extreme natural forces exerted upon the super alloy within the shaft, the resulting super alloy offers greater strength, tensile strength, and elastic modulus than the common super alloys available on the market.

The super alloy production device may be comprised of a pour spout, a crucible, and a retraction component. The pour spout and the crucible cooperate within the super alloy production device to expose the mixture of metals to the extreme conditions within the shaft which thereby enable the natural deep earth forces to act upon the metals resulting in the formation of the super alloy. The retraction component may utilize the guide ways for extending and retracting the super alloy production device within the shaft.

During use, the mixture of molten metal is transported within the crucible to the base of the shaft, where the molten metals are poured through the pour spout into a rock cut crucible at the base of the shaft. At the base of the shaft, the mixture of metal is exposed to the extreme conditions of the deep earth whereby the mixture chemically reacts to form the super alloy. Before the super alloy hardens the super alloy production device may retrieve the rock cut crucible to bring the super alloy to the surface for industrial manufacturing. The resulting super alloy may be utilized in a variety of industrial devices including ships, planes, vehicles, train engines, tools and medical devices.

The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The exemplary embodiment was chosen and described in order to best explain the principles of the invention and its practical application, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. 

1. A method of production for a super alloy comprising the steps of: boring a hole at a depth ranging from about 12 kilometers to about 20 kilometers to create said shaft; manufacturing the shaft, where said shaft includes at least one guide way; maneuvering a super alloy production device to a base of said shaft; exposing a mixture of metals within said super alloy production device to temperature and pressure within said shaft; combining said mixture of metals within said super alloy production device to form a super alloy; removing said super alloy from said shaft with said super alloy production device; and incorporating said super alloy into at least one industrial device.
 2. (canceled)
 3. The method of production for a super alloy according to claim 1 further comprising the step of retracting said super alloy in a crucible within said super alloy production device before removal.
 4. The method of production for a super alloy according to claim 1 further machining said super alloy with a diamond tipped machine to incorporate said super alloy into the at least one industrial device. 